Melting apparatus



United States Patent O 3,186,823 MELTHNG APPARATUS Theodore Novack, Big Flats, NX., assigner to Corning Glass Works, Corning, NX., a corporation of New York Filed Jan. 4, 1962, Ser. No. 164,338 Claims. (Cl. 45E- 335) This invention relates to melting apparatus, and more particularly to improved -apparatus for melting and lining vitreous or glass-like materials.

The melting and lining of speciality glasses, especially those which are readily crystallizable or devitriiiable, has produced problems which have rendered the known types of melting apparatus completely unacceptable. Although many of the specialty glasses are relatively hard glasses and processed at compartively high temperatures, which of course facilitate flning, the problem of undesirable crystallization still exists. I have found that when raw batch is charged directly into a melt of such readily devitriliable specialty glasses, the thermal shock of the relatively cold batch produces random crystallization and segregation within the melt, resulting in the production of a heterogeneous composition. In order to alleviate the problem of crystallization I deemed it advisable to premelt the charge and continuously deliver such charge in a molten condition to a lining chamber. However, due to the relatively high softening point and surface tension peculiar to some specialty glasses, a premelter had to be designedY which would not only elliciently and continuously melt such specialty glasses without incurring the undesirable devitrication or crystallization, but also which would facilitate the continuous flow of such high surface tension glasses to provide a practical llow rate to the'liner.

In brief, my invention encompasses the utilization of an inverted conical premelter which provides a relatively large surface area per unit volume to facilitate the melting of the batch supplied thereto without devitriiication. The premelter is positioned above a relining chamber or Crucible having a hollow frusto-conical baflle member positioned therewithin, and into which the molten charge from the premelter is initially directed. The baille is provided with a plurality of orifices or openings adjacent the bottom thereof, through which molten material must pass before being discharged from the lining tank or chamber. This particular batlle construction not only lends considerable strength to the cylindrical tank, but also insures that the molten material is maintained within the lining tank for a period necessary for adequate lining.

It thus has been an object of my invention to provide improved melting apparatus for melting and lining vitreous or glass-like materials.

. A further object of my invention has been to devise novel construction for a premelter which not only provides etiicient melting of raw batch, but which also facilitates the delivery of the molten charge therefrom.

An additional object of my invention has been to provide an improved lining tank having a novel baille construction which retains the molten charge delivered thereto for a period of time sullicient to insure complete fining before it is discharged from the tank.

These and other objects of my invention will be more apparent to those skilled in the art from the following disclosure and accompanying drawings in which:

FIGURE 1 is a side elevational view in section of an improved melting and lining apparatus embodying my invention;

FIGURE 2 is a top plan view of the premelter shown in FIGURE l; and,

FIGURE 3 is a fragmental side elevational View in section of a modified baille which may be utilized in the lining tank shown in FIGURE 1.

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Referring now to the drawings and particularly FlG- URES 1 and 2, the melting apparatus 10 is composed of two main parts comprising a premelter 11 and a refining tank or chamber 12. The premelter 11 is positioned above the lining tank l2 and is preferably spaced apart therefrom by means of blocks 13 which provide an opening or outlet between the premelter and the reiiner for gases emanating from the refining tank.

The premelter 11 comprises-an outer cylindrical refractory tube or shell 14, an inner concentric refractory lining such as high temperature .castable cement 15, and a refractory bottom slab 16 and cover plate 17. An inverted cone or conical chamber 18 is fitted into an opening formed in the cover plate and may extend downwardly through an orilice in the bottom slab. A tirebox 19 is formed between the cone 18 and the inner lining 15, and heat is supplied thereto by a burner 253 which lires tangentially about the inner surface o-f the liner 15.

In order to prevent the contamination of the specialty glasses to be melted by such unit, many of which are extremely incompatible with ordinary refractories, the conical chamber 18 is preferably made of platinum or platinum-rhodium alloys. To achieve maximum melting elliciency I have found that it is necessary to construct the conical chamber in such a manner so that a large surface area per unit volume is produced. Although cones with larger divergent angles may be utilized, I prefer to maintain the angle between the side wall portions and the axis of the cone below 15 degrees. With larger angles, not only is the proportion between surface area and unit volume decreased, but also the eiiectiveness of draining the melted batch from the premelter is materially reduced.

The premelter 11 is shown resting on blocks 13 which are positioned on a refractory cover plate 21 of the refining chamber 12. Refractory liners 22 and base plates Z3 cooperate with the cover plate 21 to form a lirebox or combustion chamber 24 within the reiining chamber 12. Heat may be supplied thereto by means of a plurality of burners 25 of the type utilized in the premelter. A lining Crucible 26, preferably of platinum or platinum-rhodium alloy, backed by a refractory liner 27, is positioned within the chamber 24.

Although the lower cylindrical end portion 18a of the inverted cone 1S is shown extending downwardly adjacent an exhaust port 19a and terminating above a cylindrical upper portion 23a of a frusto-conical baille member 2S positioned within the lining crucible 26, it may extend through the port and terminate adjacent portion 28a if desired. As shown, the cylindrical portion Za of the baille member 28 extends upwardly through an opening formed in the cover plate 21 and initially receives the molten batch supplied by the conical chamber 18 of the premelter 11. A flange portion 23h may extend radially outwardly from the lower end of the baille member 28 to facilitate the positioning and centering of the baflle member within the lining crucible 26. A pluralityof openings or annular orilices 29 extend through the baille member 28 adjacent a lower portion thereof. Bubbler tubes 3Q may be positioned within the baille member 28 to facilitate the lining of the material delivered thereto.

A vented overllow pipe 31 communicates with the lining crucible 26 to maintain a substantially constant glass level therewithin. An outlet or delivery tube 32 communicates with a side wall portion of the lining Crucible 26 below the glass level maintained by the overliow pipe 31. A normally closed or frozen drain tube 33 communicates with the bottom portion of the lining crucible 26. A burner 34 is positioned adjacent the outlet end of the drain tube 33 to melt the frozen plug inherently formed Within the tube 33, and thereby facilitate the changing of the melt composition within the Crucible by providing means for quickly draining the melt contained therewithin.

disease Referring now to FIGURE 3 `a fragmental section of a modied truste-conical baf'ne E28 is shown which maybe utilized in the lining crucible 26 of FIGURE l. The modiiied member i2?) likeV baille member 28, has radially extending ilange portions 123!) which are utilized to position and center the baille member within the lining crucible 26. However, in place of the annular oriilces present in baille member 23, the member l-ZS has a plurality of rectangular saw-tooth openings 129 adjacent the bottom thereof which provide for the egress ofthe molten glass-like material delivered to the baille member from the premelter.

In operation, solid batch material is delivered .tothe inverted cone or conical chamber 18. The burner 2t), which is directed tangentially about the inner surface of the liner 1:3', supplies an even heat to the inclined wall portions of the cone l to melt the batch in contact with such wall portions. The melted batch is delivered downwardly along the inner surface of the cone 18 and outwardly through the lower cylindrical portion 18a where it is charged in a molten condition into the interior of the `frusto-conical baille member.

The molten charge delivered to the frusto-conical baille Vmember must pass through the openings formed adjacent the bottom thereof before being discharged from the iining crucible 26 through outlet or delivery tube 32. Al-

though the molten charge delivered to the baille memberV Y has a tendency to egress through the openings inthe bottom thereof to seek its own level within the crucible 2, the material is maintained within the baille member a suilicient period to insure complete lining. The utilization of bubbler tubes 36 facilitates and enhances the degree of ning obtained. Gases removed from the melt are free to egress from the cylindrical upper portion of'v the baille member through the space formed between the premelter and the cover plate by means ofthe block 13 to the atmosphere. v

The overflow pipe 3l, which Ais vented to the atmosphere, maintains the glass level within the Crucible at a substantially constant level above the outlet or delivery tube 32.

The melting apparatus l@ is extremely` versatile and may be adapted to various specialty glasses. When itis desired to change the glass being melted and iined, the crucible Z6 may be easily drained by energizing the burner 34 to melt the normally frozen plug formed in the end of the drain tube 33, whereupon all of the molten material within the Crucible 26 will be drained therefrom. Accordingly the premelter may be emptied and recharged with the new material to be melted or an additional premelter containing the new batch may be substituted, and the operation renewed with the new material.

Although I have disclosed apparatus employing the now preferred embodiment of my invention, it will -be readily apparent to those skilled in the art that various changes, modifications and additions may be made thereto without departing from the spirit and scope of the invention as deiined in the 'appended claims.

I claim:

1. A two-zone apparatus for transforming solid batch material into a homogeneous molten mass comprising, a iirst zone for melting solid batch material and delivering it to a second zone for lining, said iirst zone being positioned labove said second zone, said iirst zone including an inverted conically-shaped container having an open upper end portion for receiving solid batch material and a lower open end portion for delivering molten charge therefrom, said second zone including a receptacle positioned below said lower end of the conically-shaped container for collecting and reiining the molten charge delivered by such lower open end portion, an enclosing baille member positioned within and extending above said receptacle in axial alignment with said lower open end portion for initially receiving l therewithin the molten charge from `said lower end, a heated refractory housing surrounding said receptacle and closing the upper end thereof to the atm0sphere,'said baihe member extending upwardly through said refractory housing and communicating with the atmosphere intermediate said first and second zones to facilitate the removal of gases from the molten charge within such baille, means adjacent a bottom portion of said bale member for ilowing refined molten material from the interior thereof to the remainder of said receptacle, and discharge means communicatingwith a side wall portion of said receptaclej below the surface of the molten material retained therein'for delivering such material.

2.. YApparatus as defined in claim 1 wherein a drain tube communicates with a bottom portion of s'aidjcrucible and' extends downwardly threfrom a suilicientdistance so that' a frozen plug of the material being gtreated is formed therewithin, and a burner unit is, positioned adjacent the lower end of said drain tube to fuse the frozen plug and facilitate the draining of the moltenV material from the Crucible.

3. Melting and rening apparatus` foriransforming solid batch material into afhomogeneous molten mass comprising, a premelter for continuously meltingv solid batch material into a molten charge, a closed reiining chamber positioned below said premelter to receive the molten charge therefrom, means for heating the reiining chamber to maintain the molten charge delivered thereto of openings formed in said baille member adjacent a bottom portion thereof for flowing iined molten material,

radiallyoutwardly from the interior of said `baille memer to the remainder of said reiining chamber, overilow means for maintaining a substantially constant level of molten material within said reiining chamber, and outlet means communicating withv a side wall portion of said reining chamber below said overilow means for deliveringV the reiined molten mass from said reiining chamber- 4. Improved apparatus for melting Vand lining fusible batch material comprising, a ymeltingchamber for melting solid batch material and delivering such batch material in 'a molten state to a reiining vessel, a refractory housing surrounding and enclosing said refining vessel from the atmosphere, means within said'housing for supplying heat. to said reiining vessel and maintaining theV fused batch delivered thereto in a molten condition, a hollow frusto-conical baille member positioned within said reiining vessel and extendingupwardly through said refractory housing in close adjacency with said melting chamber to initially receive the molten charge from said melting chamber, bubbler means positioned within said hollow baille member for reiining the molten material delivered thereto, said baille member being vented at its upper end directly to the atmosphereY to facilitate the removal of gases discharged from the molten mass retained therein, a pluralityrof passageways communicating between the interior of said baille member and the reiining vessel to facilitate the deliverance of reiined material from said baille member to the remainder of said reiining vessel, and means communicating with the molten material within the reiining vessel intermediate its upper and lower extent for withdrawing the reiined molten materialfrom said reiining vessel.

5. Improved apparatus for melting and lining glass-likek opening for receiving solid batch material and la lower outlet opening for delivering such batch material in a molten state to the reiining chamber, an upwardly open Crucible positioned within said refining chamber, a refractory housing surrounding said Crucible and closing the upper end thereof to the atmosphere, a hollow baille member of frusto-conical shape positioned Within said Crucible and extending upwardly through said refractory housing in axial alignment with the outlet opening of said melting chamber to initially receive the molten batch from said melting chamber, bubbler means positioned Within said baille member to facilitate reinement of the molten material delivered thereto, said baille member being vented at its upper end directly to the atmosphere intermediate said melting chamber and said rening chamber to provide for the removal of gases expunged from the molten material retained therewithin, Aa plurality of passageways adjacent a bottom end portion of said baille member communicating between the interior and exterior thereof for passing the refined material radially outwardly from said baille member to the remainder of said crucible,

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a combustion chamber within said housing and .surrounding said Crucible for maintaining material delivered thereto in a molten condition, overflow means for maintaining a substantially constant glass level within said Crucible, and outlet means communicating with the side wall portions of said crucible below said overllow means for delivering rened molten material therefrom.

References Cited by the Examiner UNITED STATES PATENTS DONALL H. SYLVESTER, Primary Examiner. WILLIAM B. KNIGHT, Examiner. 

1. A TWO-ZONE APPARATUS FOR TRANSFORMING SOLID BATCH MATERIAL INTO A HOMOGENEOUS MOLTEN MASS COMPRISING, A FIRST ZONE FOR MELTING SOLID BATCH MATERIAL AND DELIVERING IT TO A SECOND ZONE FOR FINING, SAID FIRST ZONE BEING POSITIONED ABOVE SAID SECOND ZONE, SAID FIRST ZONE INCLUDING AN INVERTED CONICALLY-SHAPED CONTAINER HAVING AN OPEN UPPER END PORTION FOR RECEIVING SOLID BATCH MATERIAL AND A LOWER OPEN END PORTION FOR DELIVERING MOLTEN CHARGE THEREFROM, SAID SECOND ZONE INCLUDING A RECEPTACLE POSITIONED BELOW SAID LOWER END OF THE CONICALLY-SHAPED CONTAINER FOR COLLECTING AND REFINING THE MOLTEN CHARGE DELIVERED BY SUCH LOWER OPEN END PORTION, AN ENCLOSING BAFFLE MEMBER POSITIONED WITHIN AND EXTENDING ABOVE SAID RECEPTACLE IN AXIAL ALIGNMENT WITH SAID LOWER OPEN END PORTION FOR INITIALLY RECEIVING THEREWITHIN THE MOLTEN CHARGE FROM SAID LOWER END, A HEATED REFRACTORY HOUSING SURROUNDING SAID RECEPTACLE AND CLOSING THE UPPER END THEREOF TO THE ATMOSPHERE, SAID BAFFLE MEMBER EXTENDING UPWARDLY THROUGH SAID REFRACTORY HOUSING AND COMMUNICATING WITH THE ATMOSPHERE INTERMEDIATE SAID FIRST AND SECOND ZONE TO FACILITATE THE REMOVAL OF GASES FROM THE MOLTEN CHARGE WITHIN SUCH BAFFLE, MEANS ADJACENT A BOTTOM PORTION OF SAID BAFFLE MEMBERS FOR FLOWING REFINED MOLTEN MATERIAL FROM THE INTERIOR THEREOF TO THE REMAINDER OF SAID RECEPTACLE, AND DISCHARGE MEANS COMMUNICATING WITH A SIDE WALL PORTION OF SAID RECEPTACLE BELOW THE SURFACE OF THE MOLTEN MATERIAL RETAINED THEREIN FOR DELIVERING SUCH MATERIAL. 